Method for restoration of furniture



United States Patent 3,310,613 METHOD FOR RESTORATION 0F FURNITURE Herbert John Lundberg, 175 Van Nostrand Ave.,

Jersey City, NJ. 07305 No Drawing. Filed Oct. 28, 1963, Ser. No. 319,597 12 Claims. (Cl. 26436) This invention relates to a method and more especially to a'new and improved method for restoring furniture, and particularly furniture having cushioning or padding enclosed by a fabric. Additionally the invention relates to a novel method for producing such furniture.

The use of furniture of the type having cushioning or padding enclosed by fabric over a period of several years not infrequently results in the cushioning or padding irreversibly compressing and/or shifting from one portion of the furniture to another portion or portions thereof. This occurs in the seat cushions, arms and backrests of sofas, chairs, loveseats, etc. The result is an unsightly, uncomfortable article of furniture incapable of retaining its original shape and being lumpy appearing and sagging. Yet while the cushioning is in unsatisfactory condition within the fabric, the fabric and frame are frequently in good condition and hence it is not desired to junk the furniture.

However the restoration or repair of such furniture by the replacement of the cushioning or packing tends to be an expensive, involved job involving the cutting of the stitching in the fabric to enable the removal of the old cushioning or padding followed by the insertion of new cushioning or padding within the fabric and rc-stitching. Further, not infrequently it is necessary the article of furniture to be restored be removed from the home and taken to the repairmans shop, and consequently may be absent from the owners home for a prolonged period.

One object of the present invention is to provide a novel method for restoring furniture of the type having cushioning or padding material enclosed by a fabric, for instance padded or stuffed sofas, chairs or loveseats, which can be carried out relatively inexpensively and simply without necessitating the cutting of stitching and removal of cushioning or padding from between the fabric.

Another object is to provide a do it yourself method for restoring furniture of the type having cushioning or padding enclosed by fabric, which method can be readily practised by a housewife.

A further object is to provide a novel method for producing new furniture of the type wherein cushioning or padding is enclosed by a fabric envelope.

Additional objects and advantages will be readily apparent as the invention is hereinafter described in more detail.

The method of the present invention involves in its broader aspects, inserting a small diameter, readily penetratable enclosed conduit, for instance a needle-shaped conduit, through a porous fabric envelope and into a cavity enclosed thereby, the conduit communicating at its opposite end portion with a container containing under pressure a composition containing a mixture of an aqueous rubber latex. In addition to the latex, the liquid mixture within the container contains a propellant, the mixture being confined in the container under the pressure of the propellant. The composition is released from the container through the conduit whereby the composition is propelled therethrough by the propellant and in-. troduced into the cavity wherein it immediately or substantially immediately foams. Due to the incoming foam, the fabric moves to its intended position and in addition serves as a mold for the foam. The rubber foam is then cured in situ. v

The rubber latex is a natural rubber latex or a synthetic rubber latex. Exemplary of the synthetic rubber latices are those of rubber polymers and copolymers, for instance latices of a butadiene-styrene copolymer (3:1 weight ratio, respectively) marketed under the trademark name GR-S rubber, polychloroprene marketed as neoprene and a copolymer of butadiene and acrylonitrile marketed under the trademark name GR-N. The natural rubber latex as Well as the synthetic latices are obtainable in commerce. Prior to dispensing as foam, the neoprene latex should be maintained at a temperature of about 40 F. The propellant of this invention, which also functions to cause foaming, includes, for example, a gas such as Freon, air, or carbon dioxide. Freon is a halogenated alkane or mixture of such alkanes with each alkane containing not more than two carbon atoms per molecule and also containing at least one fluorine atom. The atomic weight of each halogen atom substituted on the alkane does not exceed 36. Exemplary of such propellants are trichlorofluoromethane, dichlorodifluoromethane, chlorotrifluoromethane, chlorodifluoromethane, 1,1,2-trichloro-1,2,2-trifluoroethane and sym-dichloro-tetrafluoroethane. Mixtures of such compounds are also utilized and such mixtures include dichlorodifluoromethane and sym-dichloro-tetrafluoroethane, trichlorofluoromethane and dichlorodifluoromethane and sym-dichloro-tetrafluoroethane and 1,1,2-trichloro-1, 2,2-trifluoroethane.

In addition to the rubber latex and propellant, the composition while in the container under pressure will preferably also contain an agent to facilitate foaming, as well as a softening agent or plasticizer and an antioxidant. Exemplary of the foaming agent are the potassium or ammonium soaps of stearic and/or palmitic acids; of the softening agent rosin oil or mineral oil, and of the antioxidant phenyl-u-naphthylamine and p-aminophenol. A vulcanization accelerator may also be an ingredient of the composition in the container, and exemplary of suchv accelerator is diphenylguanidine and mercaptobenzothiazole.

The latex-containing composition of this invention is enclosed in a pressure-tight container from which it is propelled and dispensed as foam as needed by the propellant. The container is filled with the desired composition of rubber latex and the other ingredients, if desired, and the propellant in preferably the proportions hereinafter set forth. The rubber latex, other ingredients if used, and propellant may be separately or simultaneously introduced therein. The propellant is supplied into the container in amount corresponding to a supraatmospheric pressure within the range of preferably about 5-50 pounds per square inch gauge at 70 F. When Freon is the propellant, it is preferably supplied into the container under a pressure above its vapor pressure at the ambient temperature, so that the propellant is in liquid phase except for a small amount thereof ingaseous phase that fills the head space of the container.

The container is suitably a can having a cylindrical side wall extending to form an enclosing continuous top Wall, and also having a suitably attached bottom wall. An outlet valve is secured in an opening in the top wall of the can, the valve comprising a tube having an inturned flange at its inner end with the inturned flange forming a valve seat. A valve plug secured to a valve stem is resiliently maintained in engagement with the valve seat by a spring which is compressed between the flange and an annular flange or stop secured to the valve stem. A nozzle or discharge conduit is secured to the upper end of the tube which forms part of the valve as aforesaid, with this nozzle extending laterally from the tube. The stem extends through an opening in the nozzle and is provided with a push button which may be depressed to open the valve. A tube is fitted over the first mentioned tube within the can and extends to a point near the juncture of the side and bottom walls of the can substantially in line with the nozzle, to assure expulsion of virtually all of the can contents when the can is tilted in the direction of the nozzle. A needle-shaped discharge conduit is secured by being threadably engaged to the corresponding threaded end or otherwise secured to the end of the laterally extending tube opposite its end closest to the push button. The needle-shaped conduit is preferably tapered from a larger diameter end portion secured to the lateral tube to a smaller diameter end portion at its opposite end. Typical dimensions of the needle-shaped discharge conduit is a length of about 2-4 inches, an inner diameter at its end of insertion of 2 /l6", and a larger inner diameter at its opposite end sufiiciently large to fit over the outer end portion of the discharge tube of the can or container by a screw-on connection or otherwise. When a screw-on connection is employed, the larger diameter end portion of the conduit is threaded on its inner surface while the discharge tube is correspondingly threaded on the outer surface of its outer end portion. The can is made of a material capable of withstanding the elevated pressures therewithin, for instance of a suitable metal, and may be of the type utilized for aerosol shaving lather although preferably somewhat larger to hold a greater amount of the latex.

Prior to releasing the latex from the pressurized container, the composition is mixed in the container by agitation induced by shaking. The needle-shaped or other readily penetratable conduit of the container is then inserted through the porous fabric enclosing the cushioning or padding material of the article of used, out-of-shape furniture to be restored, and into the irregular shaped cavity enclosed thereby. If possible, the conduit is desirably inserted under an overlapping flap of material at a seam or under a tag on the article, to conceal any penetration opening made in the fabric. The valve of the container is then opened by depressing the push button, whereby the rubber latex is discharged from the outlet end of the conduit into the cavity and substantially immediately forms therein. The foam is formed by the gaseous propellant forming a multiplicity of fine gas bubbles in the latex which, after curing, provides a soft sponge having good strength and a homogeneous character. The foam will continue to rise for a brief period while in the cavity, whereby the fabric of the out-of-shape furniture article will rise to its original shape or position due to the rising and newly-incoming forming foam. When sufiicient of the foam has been injected to restore the article to its original shape, the valve is permitted to close and the needle withdrawn from the fabric. The foam is then cured, i.e. converted into a solid foam rubber. The curing is effected by holding or storing the article of furniture with the foam in place beneath the cloth at room temperature for a period sufficient for the foam to become solid, The time of curing will vary to a considerable extent depending on the type of rubber and the additives. For a natural rubber latex, typical curing times are about 10-21 days. Similar curing times are required when synthetic rubber latex is employed. The housewife or individual will know when the foam has solidified sufiiciently for use by manipulating the article of furniture by hand. The pertinent area of restoration will be resilient and shape regaining if cured sufiiciently, as contrasted with being non-resilinet and not regaining its previous shape upon withdrawal of hand or finger pressure if not cured sufficiently. Should a vulcanization accelerator be employed, the article of furniture with injected foam in place should be heated at the pertinent area to achieve vulcanizing, for instance by means of an infrared or sun lamp which is often available in the household or may be borrowed from a neighbor, etc. Care should be taken so as not to damage the fabric during the heating. The vulcanization temperature will range from about 190 C.-235 C. The time of vulcanization will vary considerably depending on whether a natural or synthetic rubber is employed, the particular accelerator utilized, etc. During the curing period, water vapor and a portion of the propellant gas pass out of the foam and through the pores of the fabric and into the atmosphere, without any significant injury to the fabric. The proportions of ingredients of a preferred latex composition of this invention, exclusive of the propellant, are preferably, by weight, from about %95% of a natural or synthetic rubber latex, from about 2%6% of foaming agent, from about 2%6% of plasticizer or softening agent, and from about 1%3% of antioxidant. When the vulcanization accelerator is employed, such accelerator is utilized in amount of preferably from about l%-2% by weight (based on the rubber latex). The latex, whether of natural or synthetic rubber, is an aqueous dispersion of the natural or synthetic rubber. Typical rubber concentration of the latex is about 35% by weight.

Examples of latex composition of this invention exclusive of the propellant and not specifying the latex alone (which can be used alone with good results together with the propellant), are set forth hereafter.

COMPOSITION A Percent by weight Natural rubber latex (an aqueous dispersion of natural rubber) Softening agent, rosin oil 2 Foaming agent, potassium soap of mixture of steraic and palmitic acids 5 Antioxidant, p-aminophenol 3 COMPOSITION B Synthetic rubber latex (an aqueous dispersion of a rubber copolymer of butadiene and styrene marketed Synthetic rubber latex (an aqueous dispersion of a copolymer of butadiene and acrylonitrile marketed as GR-N rubber) 93 Softening agent, rosin oil 3 Foaming agent, potassium soap of mixture of stearic and palmitic acids 3 Antioxidant, p-aminophenol 1 After injection of the foam and withdrawal of the conduit from the fabric, the conduit may be removed from the laterally-extending tube and washed, for instance with water or a conventional cleaning fluid, preferably the latter. Alternatively, another similar unused conduit may be secured onto the laterally-extending tube to replace the used conduit. To provide for this latter occurrence, a number of extra needle-shaped or otherwise shaped readily penetratable conduits could be secured to the container sidewall, for instance with Scotch tape.

The furniture restorable in accordance with this invention includes that frequently referred to as stuffed or overstuffed and foam furniture. Such furniture includes a frame of wood or other material, cushioning or padding over the frame, and a fabric enclosing the cushioning or padding. The cushioning or padding may be of sponge or foam rubber, polyurethane foam, or of cellulosic or other padding material, for instance of textile cloth scraps, sawdust, hair, etc. The enveloping fabric is usually a cloth fabric and is of cotton, silk, Wool, fiberglass or other suitable material. It is im-' portant the enveloping fabric be porous, which is the situation with the cloth fabrics specified, to enable the water vapor and other gases to escape from within the filled cavity through the pores. In addition to furniture in the home, automobile, boat, airplane, etc. seat cushions, back rests, etc. can be restored by this invention.

While the invention has been hereinbefore described in detail with regard to restoration of used furniture, it also has utility for producing new articles of furniture, for instance pillows, seat cushions, small padded chairs for children, etc. In this production, a previously prepared porous fabric envelope, for instance a completely stitched or laminated fabric envelope of a pillow or seat minus the cushioning, is impregnated with the latex foam in the cavity enclosed by the envelope by a procedure substantially identical to that previously described herein, followed by curing the rubber latex foam in situ within the fabric envelope. A previously prepared childs small chair including a frame of wood or other material with a ponous fabric covering at least partially over the frame, is also impregnated in the cavity or cavities enclosed by the fabric envelope and frame, such as, for instance, at the seat, arms and backrest by a method substantially identical to that previously described herein, followed by curing the rubber latex foam in situ within the fabric envelope. The previously prepared unfinished articles of furniture previously mentioned, which are finished by the method of this invention, are readily prepared by those of ordinary skill in the furniture art.

What is claimed is:

1. A method for restoring furniture of the type wherein cushioning or padding material is enclosed by a porous fabric, comprising inserting a small diameter, readily penetratable enclosed conduit through the fabric enclosing the cushioning or padding of a used, oubof-shape article of furniture of the type aforesaid and into a cavity therewithin, the conduit communicating at its end portion opposite the end of insertion with a container containing under pressure therein a composition comprising a liquid rubber latex and a propellant, the composition being confined in the container under the pressure of the propellant, releasing the composition from the container through the conduit whereby the composition is propelled therethrough by the propellant and introduced into the cavity wherein it immediately foams, the fabric returning to its original position due to the foam and serving as a mold therefor, and curing the latex foam in situ in the furniture article. i

2. The method of claim 1 wherein the latex is a natural rubber latex.

3. The method of claim 1 wherein the latex is a synthetic rubber latex.

4. The method of claim 1 wherein the propellant is air.

5. The method of claim 1 wherein the propellant is a halogenated alkane containing not more than two carbon atoms and also containing at least one fluorine atom, the atomic weight of each halogen atom not exceeding 36.

6. The method of claim 3 wherein the synthetic rubber of the latex is a rubber copolymer of butadiene and styrene.

7. The method of claim 3 wherein the synthetic rubber of the latex is a rubber copolymer of butadiene and acrylonitrile.

8. The method of claim 1 wherein the composition in the container comprises, exclusive of the propellant, by weight, from about 85%95% of the rubber latex,

from about 2%-6% of foaming agent, from about 2%- 6% of softening agent and from about l%2% by weight of antioxidant.

9. The method of claim 1 wherein prior to releasing the composition from the container, mixing the composition in the container by agitation induced by shaking.

10. A method for restoring a seat cushion of the type wherein cushioning or padding is enclosed by a porous fabric, comprising inserting a small diameter, readily penetratable, needle-shaped enclosed conduit through the fabric enclosing the cushioning or padding of a used outof-shaped seat cushion of the type aforesaid and into an irregular shaped cavity therewithin, the conduit communicating at its end portion opposite the end of insertion with a container containing under pressure therein a composition comprising a mixture of a liquid rubber latex and a propellant, the mixture being confined in the container under the pressure of the propellant, releasing the composition from the container through the conduit whereby the composition is propelled therethrough by the propellant and introduced into the cavity wherein it immediately foams, the fabric returning to its original position due to the foam and serving as a mold therefor, and curing the latex foam in situ in the seat cushion.

11. A method which comprises inserting a small diameter, readily penetratable enclosed conduit through a porous fabric envelope and into a cavity enclosed thereby, the conduit communicating at its end portion opposite the end of insertion with a container containing under pressure therein a composition comprising a liquid rubber latex and a propellant, the composition being confined in the container under the pressure of the propellant, releasing the composition from the container through the conduit whereby the composition is propelled therethrough by the propellant and introduced into the cavity wherein it substantially immediately foams, the fabric moving to its intended position due to the foam and serving as a mold therefor, and curing the latex foam in situ in the porous fabric envelope.

12. A method for producing an article of furniture of the type wherein a cushioning or padding is enclosed by a fabric envelope, which comprises inserting a small diameter, readily penetratable enclosed needle-shaped conduit through a porous fabric of a previously-prepared porous fabric envelope enclosing a cavity therewithin and into said cavity, the conduit communicating at its end portion opposite the end of insertion with a container containing under pressure therein a composition comprising a liquid rubber latex and a propellant, the composition being confined in the container under the pressure of the propellant, releasing the composition through the conduit whereby the composition is propelled therethrough by the propellant and introduced into the .cavity wherein it immediately foams, the fabric moving to its destined position due to the foam and serving as a mold therefor, and curing the latex foam in situ in the porous fabric envelope.

References Cited by the Examiner UNITED STATES PATENTS 2,320,425 -6/ 1943 Glaes et al. 161l59 3,030,951 4/1962 Mandarion l28-92 3,256,018 "6/1966 Baggenstoss 161-160 X EARL M. BERGERT, Primary Examiner.

C. B. COSBY, Assistant Examiner. 

1. A METHOD FOR RESTORING FURNITURE OF THE TYPE WHEREIN CUSHIONING OR PADDING MATERIAL IS ENCLOSED BY A POROUS FABRIC, COMPRISING INSERTING A SMALL DIAMETER, READILY PENETRATABLE ENCLOSED CONDUIT THROUGH THE FABRIC ENCLOSING THE CUSHIONING OR PADDING OF A USED, OUT-OF-SHAPE ARTICLE OF FURNITURE OF THE TYPE AFORESAID AND INTO A CAVITY THEREWITHIN, THE CONDUIT COMMUNICATING AT ITS END PORTION OPPOSITE THE END OF INSERTION WITH A CONTAINER CONTAINING UNDER PRESSURE THEREIN A COMPOSITION COMPRISING A LIQUID RUBBER LATEX AND A PROPELLANT, THE COMPOSITION BEING CONFINED IN THE CONTAINER UNDER THE PRESSURE OF THE PROPELLANT, RELEASING THE COMPOSITION FROM THE CONTAINER THROUGH THE CONDUIT WHEREBY THE COMPOSITION IS PROPELLED THERETHROUGH BY THE PROPELLANT AND INTRODUCED INTO THE CAVITY WHEREIN IT IMMEDIATELY FOAMS, THE FABRIC RETURNING TO ITS ORIGINAL POSITION DUE TO THE FOAM AND SERVING AS A MOLD THEREFOR, AND CURING THE LATEX FOAM IN SITU IN THE FURNITURE ARTICLE. 